Method and apparatus for attaching components to absorbent articles

ABSTRACT

Apparatus and method for applying discrete components of a first substrate to a second substrate includes a programmable servo motor having a shaft. The servo motor is programmed to rotate the shaft in a first phase and a second phase at a variable angular velocity in a single direction. The apparatus also includes a crank member connected with the shaft, a connector link connected with the crank member, and a tamper member connected with the connector link. When the shaft rotates in the first phase, the tamper member travels from a first position to a second position to displace a selected portion of the second substrate into contact with the discrete component.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is a continuation of U.S. application Ser. No.13/929,843 filed on Jun. 28, 2013, which claims priority to 61/665,928filed on Jun. 29, 2012, which are incorporated herein by reference.

FIELD OF THE INVENTION

The present disclosure relates to methods and apparatuses formanufacturing disposable absorbent articles, and more particularly,methods and apparatuses for attaching components, such as waistbands,side panels, cuffs, or other components to disposable absorbentarticles.

BACKGROUND OF THE INVENTION

Along an assembly line, diapers and various types of other absorbentarticles may be assembled by adding components to and otherwisemodifying an advancing, continuous web of material. For example, in someprocesses, advancing webs of material are combined with other advancingwebs of material. In other examples, individual components created fromadvancing webs of material are combined with advancing webs of material,which, in turn, are then combined with other advancing webs of material.Webs of material and component parts used to manufacture diapers mayinclude: back sheets, topsheet, absorbent cores, front and/or back ears,fastener components, and various types of elastic webs and componentssuch as leg elastics, barrier leg cuff elastics, and waist elastics.Once the desired component parts are assembled, the advancing web(s) andcomponent parts are subjected to a final cut to separate the web(s) intodiscrete diapers or other absorbent articles. The discrete diapers orabsorbent articles may also then be folded and packaged.

Various methods and apparatuses may be used for attaching differentcomponents to the advancing web. Some of the methods and apparatusesrelate to securing waistbands, and more particularly, elastic waistbandsto an advancing web. In some processes, elastic waistbands are adheredto an advancing web in a stretched condition. However, some existingmethods and apparatuses add cost and complexity to manufacturingprocesses. For example, the waistband material may be advanced in afirst direction, stretched, rotated, and advanced in a second directionbefore being applied to an advancing web. In addition, in order to joinwaistbands advancing in the cross direction to a continuous webadvancing in the machine direction, some processes may intermittentlydirect an advancing web toward the advancing waistband, which directsthe advancing web away from the machine direction. As a result, the webmay be mechanically strained to the point of rupture. In some processes,waistbands may be joined to the advancing web such that the waistbandsare spaced apart along the machine direction of the advancing web. Thespacing between adjacent waistbands may change from one size absorbentarticle to another size absorbent article. Such processes are not easilyconfigurable to accommodate changes in the spacing and/or size of thewaistbands. As a result, in order to change a process from producing onesize absorbent article to producing a different size absorbent article,equipment may need to be altered or replaced, which in turn adds machineand labor costs to the process.

It may be desirable to provide a process for attaching components ofabsorbent articles advancing in a cross direction to a continuous web ofabsorbent articles advancing in a machine direction. It may be desirableto provide a process and apparatus for joining components of absorbentarticles to advancing webs while minimizing the time the advancing webis directed away from the machine direction. It may also be desirable toprovide a process and apparatus adaptable for joining components ofabsorbent articles of various sizes and spacing to an advancing web.

SUMMARY OF THE INVENTION

Aspects of the present disclosure involve an apparatus for applyingdiscrete components, such as waistbands, cut from a first substrate to asecond substrate. The apparatus may comprise a drum having an outercircumferential surface and a cutter positioned to cut the firstsubstrate on the outer circumferential surface of the drum into aplurality of the discrete components. The apparatus may include aconveyor for positioning the second substrate proximate to, but not incontact with, the outer circumferential surface of the drum. Theapparatus may also comprise a programmable servo motor having a shaft,wherein the shaft continuously rotates at a variable angular velocity ina single direction. The servo motor is configured to rotate the shaft ina first phase and a second phase. The shaft is constrained to rotatefrom a first angular position to a second angular position in a firsttime in the first phase and the shaft is thereafter constrained torotate from the second angular position back to the first angularposition in a second time in the second phase. The apparatus may alsoinclude a tamper member associated with the shaft of the servo motor.When the shaft rotates in the first phase, the tamper member travelsfrom a first position to a second position to displace a selectedportion of the second substrate into contact with the discrete componenton the outer circumferential surface of the drum.

Aspects of the present disclosure may involve an apparatus for applyingdiscrete components of a first substrate to a target area of a secondsubstrate. The apparatus may comprise a programmable servo motor havinga shaft, wherein the shaft continuously rotates at a variable angularvelocity in a single direction. The servo motor is programmed to rotatethe shaft in a first phase and a second phase. The shaft is constrainedto rotate from a first angular position to a second angular position ina first time in the first phase and the shaft is constrained to rotatefrom the second angular position to the first angular position in asecond time in the second phase. The apparatus may include a crankmember connected with the shaft and a connector link connected with thecrank member. The apparatus includes a tamper member connected with theconnector link. The tamper member is positioned proximate to the secondsubstrate in line with a discrete component of the first substrate. Thesecond substrate may comprise a target area. When the shaft rotates inthe first phase, the tamper member travels from a first position to asecond position to displace the target area of the second substrate intocontact with the discrete component.

Aspects of the present disclosure also include a method for applyingdiscrete components of a first substrate to a second substrate, themethod comprising the steps of: rotating a drum about an axis ofrotation, the drum having an outer circumferential surface; advancingthe first substrate onto the outer circumferential surface of the drum;advancing the second substrate proximate to the outer circumferentialsurface of the drum, the second substrate having a first surface and asecond surface, wherein the second surface comprises a target area;cutting the first substrate into discrete components on the outercircumferential surface of the drum, the discrete components having afirst surface and an opposing second surface; continuously rotating ashaft of a motor at a variable angular velocity in a single direction,wherein the motor is configured to rotate the shaft in a first phase anda second phase, wherein the shaft is constrained to rotate from a firstangular position to a second angular position in a first time in thefirst phase, wherein the shaft is constrained to rotate from the secondangular position to the first angular position in a second time in thesecond phase; shifting a tamper member from a first position to a secondposition toward the second substrate and the outer circumferentialsurface of the drum as the shaft of the motor rotates in the firstphase; displacing the second substrate such that the target area of thesecond substrate contacts the first surface of a discrete component onthe drum; and shifting the tamper member from the second position backto the first position as the shaft of the motor rotates in the secondphase.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of an apparatus for joining discretecomponents to a continuous length of absorbent articles.

FIG. 2A is a plan view of a continuous length of absorbent articles fromFIG. 1 taken along line A-A before discrete waistbands are affixed bythe apparatus.

FIG. 2B is a plan view of a continuous length of absorbent articles fromFIG. 1 taken along line B-B after discrete waistbands are affixed by theapparatus.

FIG. 2C is a plan view of a continuous length of absorbent articleshaving discrete waistbands.

FIG. 2D is a plan view of a continuous length of absorbent articleshaving discrete waistbands.

FIG. 2E is a plan view of an exemplary absorbent article having twodiscrete waistbands.

FIG. 2F is a plan view of an exemplary absorbent article having onediscrete waistband.

FIG. 2G is a plan view of an exemplary absorbent article having onediscrete waistband.

FIG. 3A is a perspective view of a tamper apparatus.

FIG. 3B is an elevation view of a point D on the tamper apparatus ofFIG. 3A showing the reciprocating movement of the tamper member in thevertical direction in a defined trajectory.

FIG. 4A is a schematic, perspective view showing a shaft of a motorrotating from a first angular position to a second angular position, andback to a first angular position.

FIG. 4B is schematic, perspective view of a shaft of a motor in a firstangular position connected with a crank member in a first position.

FIG. 4C is a schematic, perspective view of a shaft of a motor in asecond angular position connected with a crank member in a secondposition.

FIG. 5 is an elevation view of a tamper apparatus in a firstconfiguration.

FIG. 6 is an elevation view of a tamper apparatus in a secondconfiguration.

FIG. 7 is a plot of the vertical position of point D from the outercircumferential surface of the drum with the motor operating at avariable angular velocity over one revolution overlaid with a plot ofthe vertical position of point D from the outer circumferential surfaceof the drum with a motor operating at a constant angular velocity overone revolution.

FIG. 8 is a plot of the vertical position of point D from the outercircumferential surface of the drum with the motor operating at avariable angular velocity over one revolution overlaid with a plot ofthe angular velocity of the shaft of the motor over one revolution.

FIG. 9 is a perspective side view of a tamper apparatus.

FIG. 10 is a plan view of a disposable absorbent article having adiscrete waistband and is partially cut away to show the construction ofand various features that may be included in a disposable absorbentarticle.

DETAILED DESCRIPTION OF THE INVENTION

This application claims priority to U.S. Provisional Application Ser.No. 61/665,928, filed Jun. 29, 2012, which is hereby incorporated byreference in its entirety.

The following term definitions may be useful in understanding thepresent disclosure:

“Absorbent article” is used herein to refer to consumer products whoseprimary function is to absorb and retain soils and wastes.

“Diaper” is used herein to refer to an absorbent article generally wornby infants and incontinent persons about the lower torso.

“Disposable” is used herein to describe absorbent articles whichgenerally are not intended to be laundered or otherwise restored orreused as an absorbent article (e.g., they are intended to be discardedafter a single use and may also be configured to be recycled, compostedor otherwise disposed of in an environmentally compatible manner).

“Disposed” is used herein to mean that an element(s) is formed (joinedand positioned) in a particular place or position as a macro-unitarystructure with other elements or as a separate element joined to anotherelement.

As used herein, “joined” encompasses configurations whereby an elementis directly secured to another element by affixing the element directlyto the other element, and configurations whereby an element isindirectly secured to another element by affixing the element tointermediate member(s) which in turn are affixed to the other element.

“Substrate” is used herein to describe a material which is primarilytwo-dimensional (i.e. in an XY plane) and whose thickness (in a Zdirection) is relatively small (i.e. 1/10 or less) in comparison to itslength (in an X direction) and width (in a Y direction). Non-limitingexamples of substrates include a layer or layers or fibrous materials,films and foils such as plastic films or metallic foils that may be usedalone or laminated to one or more web, layer, film and/or foil. As such,a web is a substrate.

“Nonwoven” refers herein to a material made from continuous (long)filaments (fibers) and/or discontinuous (short) filaments (fibers) byprocesses such as spunbonding, meltblowing, and the like. Nonwovens donot have a woven or knitted filament pattern.

“Machine direction” (MD) is used herein to refer to the direction of asecond substrate through a process.

“Cross direction” (CD) is used herein to refer to a direction that isgenerally not parallel to, and usually perpendicular to, the machinedirection in the XY plane of the material.

“Elastic,” “elastomer” or “elastomeric” refers to materials exhibitingelastic properties, which include any material that upon application ofa force to its relaxed, initial length can stretch or elongate to anelongated length more than 10% greater than its initial length and willsubstantially recover back to about its initial length upon release ofthe applied force. The term “inelastic” refers herein to any materialthat does not fall within the definition of “elastic” above.

“Stretchable” refers to materials that are capable of extending in atleast one direction to a certain degree without undue rupture.

The present disclosure relates to methods and apparatuses for joiningsubstrates. As discussed in more detail below, the process may beutilized in an absorbent article assembly configuration wherein discretecomponents, such as waistbands, are held on an outer surface of arotating drum. A tamper apparatus may include a tamper member thatdirects a target area of an advancing substrate into contact with thediscrete components on the drum. Adhesive may be applied to the discretecomponents and/or substrate to adhere the substrate and the discretecomponents together. The tamper member may be operatively connected withthe shaft of a servo motor. In some configurations, a crank member maybe connected with the motor shaft and connected with a connector link.The connector link operatively connects the tamper member with the crankmember. The motor shaft may be configured to continuously rotate at avariable angular velocity in a single direction. In some instances, theservo motor is configured to rotate the motor shaft in a first phase anda second phase, wherein the motor shaft is constrained to rotate from afirst angular position to a second angular position in a first time inthe first phase. In addition, the shaft may be constrained to rotatefrom the second angular position to the first angular position in asecond time in the second phase. When the shaft rotates in the firstphase, the tamper member travels from a first position to a secondposition to displace a selected portion of the substrate into contactwith a discrete component on the drum. When the shaft rotates in thesecond phase, the tamper member travels from the second position to thefirst position to move away from the substrate.

As discussed below, the tamper apparatus may include various linksand/or tracks to define the travel path of the reciprocating movement ofthe tamper member. For example, some configurations may include guidelinks that pivotally connect the tamper member to a base. The tamperapparatus may include a compressible member disposed along a bottomsurface of the tamper member. In some configurations, the tamper membermay be slidingly connected with guide bars that define a straight linereciprocating travel path.

In some joining operations, a drum is rotated about an axis of rotationand a first substrate advances onto an outer circumferential surface ofthe drum. A conveyor concurrently advances a second substrate in amachine direction adjacent to the drum. The drum may be oriented suchthat the first substrate is advanced in a cross direction with respectto the second substrate. The tamper apparatus is positioned adjacent thesecond substrate such that the second substrate is between the tamperapparatus and the outer circumferential surface of the drum. Adhesivemay be applied to the first substrate prior to or while the firstsubstrate is advancing on the drum. While advancing on the outercircumferential surface of the drum, the first substrate may be cut intodiscrete components. As the drum rotates to position the discretecomponents adjacent the second substrate on the drum, the servo motordrives the tamper member toward the outer circumferential surface of thedrum. The tamper member directs the second substrate into contact withthe discrete component on the outer circumferential surface of the drum.Adhesive on the discrete component attaches the discrete components tothe second substrate. The servo motor then drives the tamper member awayfrom the outer circumferential surface of the drum and the secondsubstrate continues advancing in the machine direction with the discretecomponent attached. The process is repeated to join each discretecomponent to the second substrate. As such, the discrete components arespaced apart from each other discrete component on the second substratein the machine direction.

The servo motor is configured to rapidly drive the tamper member towardand away from the outer circumferential surface of the drum in order tominimize the contact time between the tamper member and the advancingsecond substrate. As such, the motor angular velocity is greatest whenthe tamper member is relatively near to the outer circumferentialsurface of the drum. The angular velocity of the motor increases in thefirst phase as the tamper member moves toward the drum and decreases inthe second phase as the tamper member moves away from the drum. Byoperating the motor at variable angular velocities, the motor can beconfigured to slow down when the tamper member is away from the outercircumferential surface of the drum to allow a subsequent discretecomponent time to advance adjacent the second substrate and the drum.Furthermore, the servo motor can be re-programmed to account for changesin the desired outputs without the need to change or alter existingequipment. Additionally, the mechanism connected to the servo motor isrelatively smaller in size compared to a mechanical cam mechanism.

It is to be appreciated that although the methods and apparatuses hereinmay be configured to join various types of substrates and discretecomponents, the methods and apparatuses herein are discussed below inthe context of manufacturing absorbent articles. In particular, themethods and apparatuses are discussed in the context of joining discreteelastic components to a continuous length of absorbent articles. Whilethe present disclosure relates mainly to addition of elastic componentssuch as waistbands to diapers, it is to be appreciated that the methodsand apparatuses disclosed herein can also be applied to other discretecomponents used on diapers as well as other types of absorbent articles.For example, elastic components can include pre-stretched ears or sidepanels, cuffs placed in a side saddle process where the product's waistregions are parallel to the machine direction, or other componentsrequiring stretch in the cross direction. In other applications, thediscrete elastic components can comprise elastic topsheets for a diapercut from a substrate stretched in the cross direction before beingconnected with other diaper components, such as a backsheet. Inaddition, other applications may include the addition of variousinelastic components such as backsheets, topsheet, absorbent cores,front and/or back ears, and fastener components.

It is to be appreciated that the first substrate may be constructed fromvarious types of materials. For example, the first substrate may includea combination of layered elastic substrates such as elastic films, polyfilms, and nonwovens. In some examples, the first substrate may beconstructed from a single elastic or poly film. In yet other examples,the first substrate may be constructed from a single layer nonwoven. Itshould also be appreciated that second substrate may include variouscomponents of an assembled absorbent article, such as, for example, atopsheet and/or a backsheet. Various types of suitable materials forvarious diaper components are discussed in more detail below withreference to an example diaper embodiment.

As previously mentioned, the apparatuses and methods disclosed hereinmay be configured to join waistbands to a continuous length of absorbentarticles as the absorbent articles are being manufactured. For example,as shown in FIG. 1, a first substrate 104 may continuously advance ontoan outer circumferential surface 124 of a rotating drum 112 in astretched state. Concurrently, a second substrate 106 may advance in amachine direction MD adjacent the outer circumferential surface 124 ofthe drum 112. The drum 112 may be oriented such that the first substrateis advanced in a cross direction CD with respect to the machinedirection of the second substrate 106. Adhesive 113 may be applied byadhesive applicator 117 to the first substrate 104 before the firstsubstrate 104 advances onto the drum 112. The drum 112 may rotate at avelocity such that the outer circumferential surface 124 of the drum 112travels at the same speed as the first substrate 104. The drum 112 maybe configured with vacuum openings 103 for applying vacuum force to holdthe first substrate 104 on the outer circumferential surface 124, whilemaintaining cross directional stretch in the first substrate 104. Whilethe first substrate 104 is advancing on the drum 112, a cutter 116,shown in the form of a rotating knife roll 116 a for purposes ofillustration, may cut the first substrate 104 into discrete components102. Vacuum force may be used to maintain stretch in the discretecomponents 102 after being cut. While it is shown that the firstsubstrate 104 is cut by a rotating knife roll 116 a, it is to beappreciated that various other cutters may be used.

With continued reference to FIG. 1, the discrete components 102 areindividually transferred from the drum 112 to the second substrate 106with a tamper apparatus 136. A conveyor 202 may advance the secondsubstrate 106 in the machine direction MD. The conveyor 202 may beconfigured to periodically slow or stop the movement of the secondsubstrate 106 in the machine direction MD. For example, the conveyor 202may include a localized speed varying apparatus 203, such as shown inFIG. 1. It is to be appreciated that various types of localized speedvarying apparatuses may be used. Exemplary localized speed varyingapparatuses may include those described in U.S. Pat. No. 5,693,165issued to Schmitz on Dec. 2, 1997; U.S. Pat. No. 6,596,108 issued toMccabe on Jul. 22, 2003; and U.S. Patent Publication No. 2010/0252603published on Oct. 7, 2010. As the second substrate 106 is stopped, thetamper apparatus 136 moves the second substrate 106 into contact with adiscrete component 102, subsequently removing the discrete component 102from the outer circumferential surface 124 of the drum 112 and attachingthe discrete component 102 to the second substrate 106 with adhesive113. Vacuum may be intermittently interrupted in order to assist removalof the discrete component 102 from the outer circumferential surface 124of the drum 112. The tamper apparatus 136 then moves away from thesecond substrate 106, while the second substrate 106 and the discretecomponent 102 continue advancing in the machine direction MD. Theattachment process is repeated to join each discrete component 102 tothe second substrate 106. Exemplary processes for attaching elasticcomponents to absorbent articles are described in U.S. ProvisionalPatent Application No. 61/665,930.

FIG. 2A shows the continuous length of second substrate 106 beforeattaching the discrete components. As shown in FIG. 2A, the secondsubstrate 106 may have a plurality of target areas 115 positioned wherethe discrete components are to be attached to the second substrate 106.As shown in FIG. 2B, the discrete components 102, shown as discretewaistbands 194 for purposes of illustration, may be joined at eachtarget areas 115. Once the discrete waistbands 194 are joined, thesecond substrate 106, and thus the discrete waistband 194, may be cut inthe cross direction CD to create a first waistband 194 a on an absorbentarticle 104 and a second waistband 194 b on a subsequently advancingabsorbent article 104. In some exemplary configurations, as shown inFIGS. 2C and 2D, the second substrate 106 may be cut adjacent to thediscrete waistband 194, either before or after the discrete waistband194, thereby creating an absorbent article 150 a having only onediscrete waistband 194. In some exemplary configurations, absorbentarticles 150 a may have one discrete waistband 194 as shown in FIGS. 2Fand 2G, or may have two discrete waistbands 194 a and 194 b as shown inFIG. 2E. It is to be appreciated that the absorbent articles 150 a mayhave discrete waistbands arranged in various configurations. Asdiscussed below, the method steps disclosed herein can be carried out indifferent ways by various types of mechanisms.

FIG. 3A shows a detailed perspective view of an embodiment of a tamperapparatus 136 that may be used to join discrete components to asubstrate. As shown in FIG. 3A, the tamper apparatus 136 may include atamper member 220 operatively connected to a motor 222 at a shaft 224 ofthe motor 222. The tamper apparatus 136 may also include a crank member226 that is rotatably connected to the shaft 224 of the motor 222 in afirst portion 228 of the crank member 226 and operatively connected to aconnector link 240 in a second portion 230. The connector link 240operatively connects the tamper member 220 to the crank member 226. Thetamper apparatus 136 may also include a set of guide links 232 thatpivotally connect the tamper member 220 to a base 234. The tamperapparatus 136 may include a compressible member 250 operativelyconnected to a bottom surface 248 of the tamper member 220.

With reference to FIGS. 1 and 3A, during operation, the motor 222 isconfigured to continuously rotate the shaft 224 of the motor 222 at avariable angular velocity in a single direction. A second substrate 106may advance in the machine direction MD by a conveyor 202, while thediscrete components 102 advance in the cross direction CD on a rotatingdrum 112, such that the second substrate 106 is positioned between thetamper apparatus 136 and the discrete component 102 on the outercircumferential surface 124 of the drum 112. As the shaft 224 rotates,the crank member 226 rotates in the same direction as the shaft 224 ofthe motor 222. Subsequently, the connector link 240 and the guide links232 pivot, causing the tamper member 220 to move in the verticaldirection, Y. The shaft 224 may continuously rotate in a singledirection, causing the tamper member 220 to reciprocate toward and awayfrom the drum 112 in the vertical direction, Y. FIG. 3B shows a point Dof the tamper apparatus 136 from FIG. 3A reciprocating in the verticaldirection, Y, in a defined trajectory, T. Following the verticalpositioning of point D demonstrates the reciprocating movement of thetamper apparatus 136 as it moves toward and away from the drum 112.

FIG. 4A shows a schematic view of a motor shaft rotating from a firstangular position to a second angular position, and back to a firstangular position. With reference to FIGS. 3A, 4A, 4B, and 4C, the motor222 is configured to rotate the shaft 224 in a first phase 260 and asecond phase 262. In the first phase 260, the shaft 224 of the motor 222rotates from a first angular position 264 to a second angular position266 in a first time, causing the crank member 226 to rotate from a firstposition 280 shown in FIG. 4B to a second position 282 shown in FIG. 4C.In the second phase 262, the shaft 224 of the motor 222 rotates from asecond angular position 266 back to the first angular position 264 in asecond time, causing the crank member 226 to concurrently rotate from asecond position 282 to a first position 280. As discussed in more detailbelow, as the crank member 226 rotates from a first position 280 to asecond position 282, the tamper member 220 shifts toward the drum from afirst position to a second position. Subsequently, the crank member 226rotates from a second position 282 to a first position 280 and thetamper member 220 shifts away from the drum.

A motor 222 may be used to drive the tamper apparatus 136 such as shownin FIG. 3A. In particular, the motor 222 may, for example, be aprogrammable servo motor. For high speed manufacturing processes, suchas in the production of absorbent articles, the variable angularvelocity and requisite accelerations may require a motor with lowinertia and high torque to inertia properties. As shown in FIG. 3A, theservo motor 222 includes a gear box 223 to provide speed and torqueconversions to the tamper apparatus 136. An exemplary programmable servomotor 222 is manufactured by Rockwell Automation, Inc. of Milwaukee,Wis., under the designation MPL-B330P. It is to be appreciated that oneof ordinary skill in the art could program the servo motor if providedwith the desired tamper member outputs.

With continuing reference to FIG. 3A, the tamper apparatus 136 may alsoinclude a crank member 226. The crank member 226 may be defined by afirst portion 228 and a second portion 230. The first portion 228 of thecrank member 226 may be operatively connected to the shaft 224 of themotor 222 such that the crank member 226 rotates with the shaft 224 ofthe motor 222 in the same direction. The second portion 230 of the crankmember 226 may be rotatably connected to a first end 241 of theconnector link 240. In some exemplary configurations, bearings may beused to connect the second portion 230 of the crank 226 to the first end241 of the connector link 240.

The tamper apparatus 136 may also include a tamper member 220 as shownin FIG. 3A. The tamper member 220 may have a first portion 244 and asecond portion 246. The second portion 246 of the tamper member 220 maydefine a bottom surface 248. The first portion 244 of the tamper member220 may be operatively connected to a second end 242 of the connectorlink 240. The second portion 246 of the tamper member 220 may besubstantially perpendicular to the first portion 244 of the tampermember 220, forming a substantially T-shaped member. The bottom surface148 of the tamper member 220 may be contoured to match the contour ofthe outer circumferential surface of the drum. The bottom surface 248 ofthe tamper member 220 may be larger than a discrete component such thatthe tamper member 220 may press the second substrate against the entirediscrete component. It is to be appreciated that a tamper member 220configured for one size discrete component may be used to attachdiscrete components of various sizes. In some exemplary configurations,the tamper member 220 may be made from a light-weight metal materialsuch as, for example, aluminum or titanium.

With reference to FIG. 3A, the tamper apparatus 136 may also include acompressible member 250 disposed along the bottom surface 248 of thetamper member 220. The compressible member 250 may be made of a materialsuch as, for example, foam or rubber that compresses upon application ofpressure to the compressible member. In some exemplary configurations,the compressible member 250 may have void spaces 252 such as shown inFIG. 3A. The compressible member may have an arcuate shape to match thecontour of the outer circumferential surface of the drum. It is to beappreciated that a bottom surface 254 of the compressible member 250 mayinclude a skin 256 to prevent the tamper apparatus 136 from sticking tothe second substrate. The skin 256 may be made of a non-stick materialsuch as urethane for example.

The tamper apparatus 136 may also include guide links 232 as shown inFIG. 3A. One end of each guide link may be operatively connected to thefirst portion 244 of the tamper member 220. The other end of each guidelink 232 may be operatively connected to a base 234. While FIG. 3A showstwo guide links 232, it is to be appreciated that fewer or greater thantwo guide links 232 may be used.

In operation, a continuous length of second substrate is advanced in themachine direction MD and discrete components are advanced in thecross-direction CD proximate to the tamper apparatus as shown in FIG. 1.The second substrate 106 advances in the machine direction MD proximateto the tamper apparatus 136 by a conveyor 202. The second substrate 106may be defined by a first surface 107 and a second surface 108. At thesame time as the second substrate 106 advances in the machine directionMD, discrete components 102 advance on the outer circumferential surface124 of the rotating drum 112 in the cross direction CD such that thesecond substrate 106 is between the tamper apparatus 136 and thediscrete components 102 on the outer circumferential surface 124 of thedrum 112. The discrete components 102 may be defined by a first surface109 and a second surface 110. As discussed in more detail below, thetamper apparatus 136 is configured to reciprocate from a firstconfiguration to a second configuration and back to a firstconfiguration to join the first surface 109 of the discrete components102 to the second surface 108 of the second substrate 106.

FIG. 5 shows a front elevation view of a tamper apparatus 136 in a firstconfiguration 284. In a first configuration 284, the crank member 226 isin a first position 280 and the tamper member 220 is in a first position207, positioned away from the second substrate 106 and the outercircumferential surface 124 of the drum 112. FIG. 6 shows a frontelevation view of a tamper apparatus 136 in a second configuration 286.In a second configuration 286, the crank member 226 is in a secondposition 282 and the tamper member 220 is in a second position 209,pressing the second substrate 106 against the discrete band 102 on theouter circumferential surface 124 of the drum 112.

As shown in FIGS. 5 and 6, the contour of the bottom surface 248 of thetamper member 220 may match the contour of the outer circumferentialsurface 124 of the drum 112 such that the second substrate 106 uniformlypresses the discrete components 102 between the tamper member 220 andthe outer circumferential surface 124 of the drum 112. It is to beappreciated the discrete components may advance by a conveyor or avariety of other apparatuses having a contours different than that ofthe outer circumferential surface of the drum.

Referring to FIGS. 1, 3A-6, the servo motor 222 continuously rotates theshaft 224 of the motor 222 at a variable angular velocity in a singledirection. In one revolution, the tamper apparatus 136 starts in a firstconfiguration 284. In the first configuration 284, the shaft 224 of themotor 222 starts at a first angular position 264 and the crank member226 also starts in first position 280. As the shaft 224 of the motor 222rotates, the crank member 226 rotates in the same direction. The secondportion 230 of the crank member 226 rotates in a circular path aroundthe shaft 224 of the motor 222. At the same time, the bearings thatconnect the crank member 226 to the connector link 240 cause the firstend 241 of the connector link 240 to also rotate in a circular patharound the shaft 224 of the motor 222. As the first end 241 of theconnector link 240 rotates, the tamper member 220 reciprocates downwardin the vertical direction toward the first surface 107 of the secondsubstrate 106 and the set of guide links 232 pivot. The guide links 232limit the movement of the tamper member 220 to a defined trajectory, T,as the tamper member 220 moves toward the drum 112. The tamper member220 contacts the first surface 107 of the second substrate 106 as theshaft 224 of the motor 222 approaches the second angular position 266,causing the second substrate 106 to be pressed against the first surface109 of the discrete component 102 on the outer circumferential surface124 of the drum 112. The tamper apparatus 136 is in the secondconfiguration 286 when the tamper member 220 presses the secondsubstrate 106 against the discrete component 102 on the outercircumferential surface 124 of the drum 112. The adhesive 113 on thefirst surface 109 of the discrete component 102 acts to adhere thesecond surface 108 of the second substrate 106 to the first surface 109of the discrete component 102. To complete one revolution, the tamperapparatus 136 shifts from the second configuration 286 back to the firstconfiguration 284. The shaft 224 of the motor 222 continues rotatingfrom the second angular position 266 back to the first angular position264 and the crank member 226 rotates from a second position 282 to afirst position 280. The tamper apparatus 136 continuously rotates backand forth from the first configuration 284 to the second configuration286 through multiple revolutions in order to join subsequent discretecomponents to the second substrate 106.

With reference to FIGS. 2A and 3A, the tamper member 220 may beconfigured to displace the target area 115 of the second surface 108 ofthe second substrate 106 into contact with the first surface 109 of thediscrete component 102. In particular, the tamper member 220 maydisplace the first surface 107 of the second substrate 106 and press thetarget area 115 of the second surface 108 of the second substrate 106against the first surface 109 of the discrete component 102 on the outercircumferential surface 124 of the drum 112.

The shaft of the motor is configured to continuously rotate at avariable angular velocity, causing the velocity of the tamper member inthe vertical direction, Y, to change during each revolution. FIG. 7shows a graph 400 of the vertical position of point D from the outercircumferential surface of the drum with the motor operating at avariable angular velocity over one revolution. FIG. 7 also includesgraph 500 of the vertical position of point D from the outercircumferential surface of the drum with a motor operating at a constantangular velocity over one revolution. With regard to graphs 400 and 500,the tamper member compresses against the drum at zero meters. Time isrepresented on the x-axis. As shown in FIG. 7, for each revolution, thetamper member is relatively near the outer circumferential surface ofthe drum for a shorter period of time when the motor is operating at avariable angular velocity compared to a motor operating at a constantangular velocity. A motor configured to rotate the shaft at a variableangular velocity can speed up and slow down through one revolution inorder to limit the time the tamper member directs the second substratetoward the outer circumferential surface of the drum. Whereas, when themotor is programmed to drive the shaft of the motor with a constantangular velocity, the motor must drive the shaft at a higher constantangular velocity in order to limit the time the motor is contacting theouter circumferential surface of the drum. However, speeding up a motoroperating at a constant angular velocity decreases the total time of onerevolution. In some exemplary configurations, the total time for onerevolution may be preselected based upon the spacing requirements of thediscrete components on the second substrate. In that case, operating themotor at a variable angular velocity may limit the time the tampermember contacts the second substrate while also maintaining thepreselected amount of time between attachment of adjacent discretecomponents.

FIG. 8 shows a graph 600 of the vertical position of point D from theouter circumferential surface of the drum with the motor operating at avariable angular velocity over one revolution. FIG. 8 also shows a graph700 of the angular velocity of the shaft of the motor over onerevolution. Time is represented on the x-axis. As shown in FIG. 8, asthe tamper member approaches the outer circumferential surface of thedrum at zero meters, the angular velocity of the shaft of the motor isincreasing. Once the tamper member is in the second position, theangular velocity is at the highest angular velocity for each revolution.The angular velocity of the shaft of the motor then decreases as thetamper member shifts away from the outer circumferential surface of thedrum. The angular velocity of the motor is at lowest angular velocitywhen the tamper member is furthest from the drum at the first position.

FIG. 9 shows a perspective side view of an embodiment of a tamperapparatus. As shown in FIG. 9, the tamper apparatus 326 may include aservo motor 322 having a shaft 324. The shaft of the motor 322 isoperatively connected to a crank member 326 at one end of the crankmember 326. The opposite end of the crank member 326 is rotatablyconnected to a connector link 340. The connector link 340 is alsorotatably connected to a tamper member 320. The tamper member 320 may beconnected with two guide bars 332 in order to limit the trajectory of apoint on the tamper member 320 to a straight line. The tamper member 320may also include a compressible member 350 having a skin 356.

With reference to FIG. 1, the conveyor apparatus 202 may be in the formof a localized speed varying apparatus 203 that may slow or stop thesecond substrate 106 in the machine direction MD. As the secondsubstrate 106 is stopped or slowed, the tamper apparatus 136 is able tomore precisely join the discrete component 102 to the second substrate106. While the second substrate 106 is temporarily stopped in themachine direction MD, the drum 112 continues to rotates in the crossdirection CD while the tamper apparatus 136 contacts the secondsubstrate 106 and discrete component 102 against the outercircumferential surface 124 of the drum 112. It is to be appreciatedthat the compressible member 250 may deform while the tamper apparatus136 compresses the second substrate 106 against the discrete component102 on the outer circumferential surface 124 of the drum 112. As aresult, the discrete component 102 may remain in the samecross-directional position relative to the second substrate 106 eventhough the drum 112 continues rotating in the cross direction CD.

A number of different products may be manufactured in accordance withthe methods described herein. For the purposes of a specificillustration, FIG. 10 shows one example of a disposable absorbentarticle 150 in the form of a diaper 152 that may include a discretecomponent 102 attached thereto in accordance with the presentdisclosure. In particular, FIG. 10 is a plan view of one embodiment of adiaper 152 including a chassis 154 shown in a flat, unfolded condition,with the portion of the diaper 152 that faces a wearer oriented towardsthe viewer. A portion of the chassis structure is cut-away in FIG. 10 tomore clearly show the construction of and various features that may beincluded in exemplary configurations of the diaper.

As shown in FIG. 10, the diaper 152 includes a chassis 154 having afirst ear 156, a second ear 158, a third ear 160, and a fourth ear 162.As discussed above, while the present disclosure discusses joiningdiscrete components in the form of waistbands to absorbent articles, itis to be appreciated that the tamper apparatus may be used to join otherdiscrete components such as ears 156, 158, 160, and 162, for example, toabsorbent articles. To provide a frame of reference for the presentdiscussion, the chassis is shown with a longitudinal axis 164 and alateral axis 166. The chassis 154 is shown as having a first waistregion 168, a second waist region 170, and a crotch region 172 disposedintermediate the first and second waist regions. The periphery of thediaper is defined by a pair of longitudinally extending side edges 174,176; a first outer edge 178 extending laterally adjacent the first waistregion 168; and a second outer edge 180 extending laterally adjacent thesecond waist region 170. As shown in FIG. 10, the chassis 154 includesan inner, body-facing surface 182, and an outer, garment-facing surface184.

As shown in FIG. 10, the chassis 154 of the diaper 152 may include anouter covering layer 186 including a topsheet 188 and a backsheet 190.An absorbent core 192 may be disposed between a portion of the topsheet188 and the backsheet 190. As discussed in more detail below, one ormore of the regions may be stretchable and may include an elastomericmaterial or layered elastic substrate as described herein. As such, thediaper 152 may be configured to adapt to a specific wearer's anatomyupon application and to maintain coordination with the wearer's anatomyduring wear.

Although the first and second ears 156, 158 as well as the third andfourth ears 160, 162 shown in FIG. 10 are illustrated as beingintegrally formed with the chassis 154, it is to be appreciated thatother embodiments may include ears that are discrete elements connectedwith the chassis. In some embodiments, the ears are configured to bestretchable. The ears may also include one or more fastener elementsadapted to releasably connect with each other and/or other fastenerelements on the chassis. A more detailed discussion of stretchable earscan be found in U.S. Pat. Nos. 4,857,067; 5,151,092; 5,674,216;6,677,258; 4,381,781; 5,580,411; and 6,004,306. The ears may alsoinclude various geometries and arrangements of stretch zones orelements, such as discussed in U.S. Pat. Publication Nos. US2005/0215972A1 and US 2005/0215973A1.

As shown in FIG. 10, the diaper 152 may include leg cuffs 196 that mayprovide improved containment of liquids and other body exudates. The legcuffs 196 may be disposed in various ways on the diaper 152. Forexample, the leg cuffs 196 may be disposed on the outer, garment-facingsurface 184 of the chassis 154; the inner, body-facing surface 182; orbetween the inner and outer facing surfaces 182 or 184. Leg cuffs 196may also be referred to as leg bands, side flaps, barrier cuffs, orelastic cuffs. U.S. Pat. No. 3,860,003 describes a disposable diaperthat provides a contractible leg opening having a side flap and one ormore elastic members to provide an elasticized leg cuff (a gasketingcuff). U.S. Pat. Nos. 4,808,178 and 4,909,803 describe disposablediapers having “stand-up” elasticized flaps (barrier cuffs). U.S. Pat.Nos. 4,695,278 and 4,795,454 describe disposable diapers having dualcuffs, including gasketing cuffs and barrier cuffs.

The diaper may be provided in the form of a pant-type diaper or mayalternatively be provided with a re-closable fastening system, which mayinclude fastener elements in various locations to help secure the diaperin position on the wearer. For example, fastener elements may be locatedon the first and second ears and may be adapted to releasably connectwith one or more corresponding fastening elements located in the secondwaist region. It is to be appreciated that various types of fasteningelements may be used with the diaper. In one example, the fasteningelements include hook & loop fasteners, such as those available from 3Mor Velcro Industries. In other examples, the fastening elements includeadhesives and/or tap tabs, while others are configured as amacrofastener or hook (e.g., a MACRO or “button-like” fastener). Someexemplary fastening elements and systems are disclosed in U.S. Pat. Nos.3,848,594; 4,662,875; 4,846,815; 4,894,060; 4,946,527; 5,151,092; and5,221,274. Additional examples of fasteners and/or fastening elementsare discussed in U.S. Pat. Nos. 6,251,097 and 6,432,098; and U.S. PatentPublication Nos. 2007/0078427 and 2007/0093769. Other fastening systemsare described in more detail in U.S. Pat. Nos. 5,595,567; 5,624,427;5,735,840; and 5,928,212. The fastening system may also provide a meansfor holding the article in a disposal configuration as disclosed in U.S.Pat. No. 4,963,140.

Components of the disposable absorbent article (i.e., diaper, disposablepant, adult incontinence article, sanitary napkin, pantiliner, etc.)described in this specification can at least partially be comprised ofbio-sourced content as described in US 2007/0219521A1 Hird, et alpublished on Sep. 20, 2007, US 2011/0139658A1 Hird, et al published onJun. 16, 2011, US 2011/0139657A1 Hird et al published on Jun. 16, 2011,US 2011/0152812A1 Hird et al published on Jun. 23, 2011, US2011/0139662A1 Hird, et al published on Jun. 16, 2011, and US2011/0139659A1 Hird, et al published on Jun. 16, 2011. These componentsinclude, but are not limited to, topsheet nonwovens, backsheet films,backsheet nonwovens, side panel nonwovens, barrier leg cuff nonwovens,super absorbent, nonwoven acquisition layers, core wrap nonwovens,adhesives, fastener hooks, and fastener landing zone nonwovens and filmbases.

In at least one exemplary configuration, a disposable absorbent articlecomponent comprises a bio-based content value from about 10% to about100% using ASTM D6866-10, method B, in another embodiment, from about25% to about 75%, and in yet another embodiment, from about 50% to about60% using ASTM D6866-10, method B.

In order to apply the methodology of ASTM D6866-10 to determine thebio-based content of any disposable absorbent article component, arepresentative sample of the disposable absorbent article component mustbe obtained for testing. In at least one embodiment, the disposableabsorbent article component can be ground into particulates less thanabout 20 mesh using known grinding methods (e.g., Wiley® mill), and arepresentative sample of suitable mass taken from the randomly mixedparticles.

The absorbent article may also include discrete components 102 a and 102b such as shown in FIG. 10 in the form of first and second waistbands194 a and 194 b. The first and second waistbands 194 a and 194 b mayprovide improved fit and waste containment. The first and secondwaistbands 194 a and 194 b may be located in the first waist region 168and/or the second waist region 170. The first and second waistbands 194a and 194 b may be configured to elastically expand and contract todynamically fit the wearer's waist.

The first and second waistbands 194 a and 194 b can be incorporated intothe diaper in accordance with the methods discussed herein and mayextend at least longitudinally outwardly from the absorbent core 192 andgenerally form at least a portion of the first and/or second outer edges178, 180 of the diaper 152. In addition, the first and second waistbands194 a and 194 b may extend laterally to include the ears. While thefirst and second waistbands 194 a and 194 b or any constituent elementsthereof may comprise one or more separate elements affixed to thediaper, the first and second waistbands 194 a and 194 b may beconstructed as an extension of other elements of the diaper, such as thebacksheet 190, the topsheet 188, or both the backsheet 190 and thetopsheet 188. In addition, the first and second waistbands 194 a and 194b may be disposed on the outer, garment-facing surface 184 of thechassis 154; the inner, body-facing surface 182; or between the innerand outer facing surfaces. It is to be appreciated that the first andsecond waistbands 194 a and 194 b shown in FIG. 10 may comprise the samematerials and/or may have the same structure. While in other exemplaryconfigurations, the first and second waistbands 194 a and 194 b maycomprise different materials and/or may have different structures. Thefirst and second waistbands 194 a and 194 b may be constructed in anumber of different configurations including those described in U.S.Patent Application No. 61/499,294; and U.S. Patent Publication Nos.2007/0142806; 2007/0142798; and 2007/0287983.

The dimensions and values disclosed herein are not to be understood asbeing strictly limited to the exact numerical values recited. Instead,unless otherwise specified, each such dimension is intended to mean boththe recited value and a functionally equivalent range surrounding thatvalue. For example, a dimension disclosed as “40 mm” is intended to mean“about 40 mm.”

Every document cited herein, including any cross referenced or relatedpatent or application, is hereby incorporated herein by reference in itsentirety unless expressly excluded or otherwise limited. The citation ofany document is not an admission that it is prior art with respect toany invention disclosed or claimed herein or that it alone, or in anycombination with any other reference or references, teaches, suggests ordiscloses any such invention. Further, to the extent that any meaning ordefinition of a term in this document conflicts with any meaning ordefinition of the same term in a document incorporated by reference, themeaning or definition assigned to that term in this document shallgovern.

While particular embodiments of the present invention have beenillustrated and described, it would be obvious to those skilled in theart that various other changes and modifications can be made withoutdeparting from the spirit and scope of the invention. It is thereforeintended to cover in the appended claims all such changes andmodifications that are within the scope of this invention.

What is claimed is:
 1. A method for applying discrete components of afirst substrate to a second substrate, the method comprising: rotating adrum about an axis of rotation, the drum having an outer circumferentialsurface; advancing the first substrate onto the outer circumferentialsurface of the drum; advancing the second substrate proximate to theouter circumferential surface of the drum, the second substrate having afirst surface and a second surface, wherein the second surface comprisesa target area; cutting the first substrate into discrete components onthe outer circumferential surface of the drum, the discrete componentshaving a first surface and an opposing second surface; continuouslyrotating a shaft of a motor at a variable angular velocity in a singledirection, wherein the motor is configured to rotate the shaft in afirst phase and a second phase, wherein the shaft is constrained torotate from a first angular position to a second angular position in afirst time in the first phase, wherein the shaft is constrained torotate from the second angular position to the first angular position ina second time in the second phase; shifting a tamper member from a firstposition to a second position toward the second substrate and the outercircumferential surface of the drum as the shaft of the motor rotates inthe first phase; displacing the second substrate such that the targetarea contacts the first surface of a discrete component on the drum; andshifting the tamper member from the second position to the firstposition as the shaft of the motor rotates in the second phase.
 2. Themethod of claim 1, wherein the discrete components advance in the crossdirection and the second substrate advances in the machine direction. 3.The method of claim 1, wherein the drum comprises a plurality of vacuumopenings on the outer circumferential surface thereof.
 4. The method ofclaim 3, wherein the discrete components of the first substrate arewaistbands.
 5. The method of claim 4, comprising applying vacuum forceto hold the waistbands in a stretched state on the outer circumferentialsurface of the drum.
 6. The method of claim 1, comprising stopping thesecond substrate in the machine direction using a localized speedvarying apparatus prior to the step of displacing a selected portion ofthe second substrate into contact with a discrete component of the firstsubstrate on the drum.
 7. The method of claim 1, wherein the angularvelocity of the shaft of the motor increases in the first phase.
 8. Themethod of claim 1, wherein the angular velocity of the shaft of themotor decreases in the second phase.
 9. The method of claim 1, whereincutting the first substrate into discrete components comprising rotatinga knife roll about an axis of rotation.
 10. A method for applyingdiscrete components of a first substrate to a second substrate, themethod comprising: rotating a drum about an axis of rotation, the drumhaving an outer circumferential surface; advancing the first substrateonto the outer circumferential surface of the drum; advancing the secondsubstrate proximate to the outer circumferential surface of the drum,the second substrate having a first surface and a second surface,wherein the second surface comprises a target area; cutting the firstsubstrate into discrete components on the outer circumferential surfaceof the drum, the discrete components having a first surface and anopposing second surface; continuously rotating a shaft of a motor at avariable angular velocity in a single direction, wherein the motor isconfigured to rotate the shaft in a first phase and a second phase,wherein the shaft is constrained to rotate from a first angular positionto a second angular position in a first time in the first phase, whereinthe shaft is constrained to rotate from the second angular position tothe first angular position in a second time in the second phase; andshifting a tamper member from a first position to a second positiontoward the second substrate and the outer circumferential surface of thedrum as the shaft of the motor rotates in the first phase.
 11. Themethod of claim 10, comprising displacing the second substrate such thatthe target area contacts the first surface of a discrete component onthe drum.
 12. The method of claim 10, comprising shifting the tampermember from the second position to the first position as the shaft ofthe motor rotates in the second phase.
 13. The method of claim 10,wherein the discrete components advance in the cross direction and thesecond substrate advances in the machine direction.
 14. The method ofclaim 10, wherein a compressible member is operatively connected with abottom surface of the tamper member.
 15. The method of claim 10, whereinthe tamper member has a bottom surface, wherein the outercircumferential surface of the drum has a contour, and wherein thebottom surface of the tamper member is contoured to match the contour ofthe outer circumferential surface of the drum.
 16. A method for applyingdiscrete components of a first substrate to a second substrate, themethod comprising: rotating a drum about an axis of rotation, the drumhaving an outer circumferential surface; advancing the first substrateonto the outer circumferential surface of the drum; advancing the secondsubstrate proximate to the outer circumferential surface of the drum,the second substrate having a first surface and a second surface,wherein the second surface comprises a target area; cutting the firstsubstrate into discrete components on the outer circumferential surfaceof the drum, the discrete components having a first surface and anopposing second surface; continuously rotating a shaft of a motor at avariable angular velocity in a single direction, wherein the motor isconfigured to rotate the shaft in a first phase and a second phase,wherein the shaft is constrained to rotate from a first angular positionto a second angular position in a first time in the first phase, whereinthe shaft is constrained to rotate from the second angular position tothe first angular position in a second time in the second phase;shifting a tamper member from a first position to a second positiontoward the second substrate and the outer circumferential surface of thedrum as the shaft of the motor rotates in the first phase; anddisplacing the second substrate such that the target area contacts thefirst surface of a discrete component on the drum.
 17. The method ofclaim 16, comprising shifting the tamper member from the second positionto the first position as the shaft of the motor rotates in the secondphase.
 18. The method of claim 16, comprising stopping the secondsubstrate in the machine direction using a localized speed varyingapparatus.
 19. The method of claim 16, wherein the angular velocity ofthe shaft of the motor increases in the first phase.
 20. The method ofclaim 16, wherein the angular velocity of the shaft of the motordecreases in the second phase.